Packaging for fragile articles within container

ABSTRACT

A unitary structure for packaging a shock sensitive article within a container is provided. The structure has a side flange adapted to contact a side end portion of the article and a number of sidewall structures disposed about the periphery of the flange which extend over the side end portion of the article to contactingly support the article. Each of the sidewalls cushions the article against shocks by having an outboard wall which operably and supportingly contacts the container and a bridge section integral with the inboard wall and the outboard wall to cushioningly space the outboard wall from the inboard wall. The structure also includes a crush depression integral to the flange, inward of the sidewall and generally extending away from the article to supportingly contact a lateral sidewall of the container thereby forming a cushion distance. The crush button is configured to absorb shock loading of the article directed generally toward the sidewall.

TECHNICAL FIELD

The present invention relates to packaging for fragile structures suchas printed circuit boards, disk drives or the like. More particularly,the invention relates to a flexible, thermally formed type of plasticpackaging, of unitary construction, which is adapted to hold suchfragile articles and to dissipate forces exerted upon shipping cartonscontaining such articles in such a manner that the articles are notdamaged if the carton is dropped or mishandled.

BACKGROUND OF THE INVENTION

Currently, the shipment of fragile articles, regardless of size andweight, requires special packaging to avoid damage to the articles. Forthis purpose, materials such as crumpled paper, nuggets of expandedfoam, and/or preformed expanded polystyrene foam is used to packagefragile articles, including but not limited to electronic articles suchas computer CPUs, computer disk drives, VCR's and the like. Thepreformed polystyrene foam material is often provided in the form of“corners” or other support pieces which envelope at least portions ofthe packaged fragile article.

Aside from being bulky, upon an initial impact, the polystyrene foamloses virtually all of its shock absorbing qualities. Thus, fragilearticles packaged with rigid pieces of expanded polystyrene foam as theprotective media are susceptible to damage from repeated shocks to thebox or container. A related disadvantage of such foam packaging is thata relatively thick piece of foam must be employed to protect a packagedarticle from impact, even though only a portion of the foam will becompressed upon impact. Also, shippers are required to select shippingcontainers, such as corrugated boxes, which are substantially largerthan the article being packaged, merely to accommodate sufficientthicknesses of polystyrene foam which can absorb only one impact.

Another disadvantage of conventional polystyrene foam is that itsbulkiness requires packagers to allot significant warehouse storagespace to the foam packaging elements prior to use. Larger containersrequire additional warehouse space, both before and after assembly, andalso take up more space per article shipped in rail cars or trailers.

Yet another disadvantage of conventional packaging for fragile articlesis that because of its bulkiness, it is not generally economicallyfeasible to ship the expanded polystyrene foam to a recycling location.Furthermore, even when the expanded polystyrene foam is recycled intoproduct, the cost of recycling is relatively large and, generally, nomore than about 25 percent recycled content can be utilized, with theremainder being virgin material. Indeed, considering the great quantityof expanded polystyrene foam which is currently in use to providefragility packaging and the general lack of adequate recycling of thismaterial, the adverse environmental impact is of staggering proportions.The present invention is directed to overcoming one or more of theabove-identified problems.

Commonly-assigned U.S. Pat. No. 5,226,543 discloses a package forfragile articles which addresses the above-listed problems, and providesa solution in the form of a unitary package having a platform portionheld a specified distance above the substrate by a peripheral wallformation which also borders the platform portion. Shock limitingformations are formed in the sidewall structure for restricting themovement of the platform portion toward the lower edge of the peripheralwall upon shock loading of the platform.

It has been found that for some applications, the amount ofthermoformable material required for manufacturing the package isexcessive, and results in an uneconomical solution to theabove-identified packaging problem.

Accordingly, it is an object of the present invention to provide animproved unitary shock-resistant package for fragile articles whichdeforms to absorb shock loading. A related object is to provide such apackage which recovers from such deformation after each shock loading toabsorb additional shock loadings.

An additional object of the present invention is to provide an improvedshock resistant package which reduces the space required for storinglarge numbers of these packages prior to their use.

Yet another object of the present invention is to provide an improvedpackage which employs recyclable material while achieving theabove-listed objects.

A still further object of the present invention is to provide a unitaryshock-resistant package which economically employs thermoformablematerial while achieving the above-listed objects.

SUMMARY OF THE INVENTION

Accordingly, unitary structure for packaging a shock sensitive articlewithin a container is provided. The structure has a side flange adaptedto contact a side end portion of the article. Integrally connected to aperipheral portion of the flange is a peripheral sidewall structure withthe sidewall structure having an inboard wall extending over the sideend portion of the article to contactingly support the article. Thesidewall cushions the article against shocks by having an outboard wallwhich operably and supportingly contacts the container and a bridgesection integral with the inboard wall and the outboard wall tocushioningly space the outboard wall from the inboard wall. The bridgesection resiliently restricts the movement of the inboard wall towardthe outboard wall to dissipate the shock loading. The structure alsoincludes at least one crush depression integral to the flange andgenerally extending away from the article to supportingly contact asidewall of the container thereby forming a cushion distance. The crushdepression is configured to absorb shock loading of the article towardthe sidewall of the container.

Preferably, two of the structures are disposed within the container tocontactingly support opposite side portions of the article and suspendthe article from the longitudinal sidewalls of the container. Also eachof the structures has a plurality of sidewall structures integrallyconnected to the peripheral edges of the flange and spaced from eachother so that each of the sidewalls may independently absorb shockloading of the article. The number and arrangement of the sidewalls istypically predicated by the configuration of the article. Each of thesidewalls may be uniquely configured to adjust the resiliency of thesidewall to improve the shock loading characteristics of the sidewall.

An alternate embodiment of an unitary structure for packaging shocksensitive article is also provided. In the alternate embodiment, atleast one foldable flap is attached to a distal end portion of one ofthe peripheral sidewall structures. The flap includes a planar portionand a shock absorbing protrusion extending outward from the planarportion. When the flap is placed in the folded position, the flapextends along the underside of the sidewall structure with the shockabsorbing protrusion and the crush depressions contactingly engaging thesidewall of the structure to facilitate the shock cushioningcharacteristics of the structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates, in a top perspective view, an article located in anenclosure in a form of packaging constructed in accordance with theembodiment of the invention, and also having a package of the inventionpositioned along an opposite side of the article;

FIG. 2 illustrates, in a perspective view of the present packagingstructure taken similar to the view of FIG. 1 with a portion shown cutaway;

FIG. 3 is a sectional view taken generally along the line 3—3 of FIG. 2and in the direction indicated generally; and

FIG. 4 is a perspective view similar to the view of FIG. 1, of analternate embodiment of a form of packaging constructed in accordancewith the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiment of the present invention provides an a unitarypacking structure 10isas shown in FIG. 1. As illustrated, the unitarypacking structure 10 is adapted to support and hold a lateral endportion 12a of a shock sensitive article 12 such as a laptop computer orthe like. The packaging structure 10 and a second packaging structure 14for holding an opposite lateral end portion of 12b the article 12, willnormally be positioned within a container 16 such as a box or corrugatedcarton. The container 16 is formed with lateral sidewalls 18 and 20.Extending between the sidewalls 18 and 20 are a top wall 22, bottom wall24 and longitudinal sidewalls 26 and 28. The packaging structures 10, 14are preferably positioned to contact the lateral sidewalls 18, 20, andthe walls 18-28 are shown in a relatively tight fitting arrangementabout the packaging structures 10, 14 and article 12. Furthermore, it iscontemplated that with articles 12 having end portions 12a, 12b ofsimilar configuration and dimensions, the packaging structure 14 will besimilarly constructed to packaging structure 10 but oriented in theopposite direction, as shown in FIG. 1.

The structure 10 is in the general form of a vertically oriented trayhaving a vertically extending central flange 30 which is adapted tocontact and support the article 12 against lateral movement. The flange30 has a peripheral edge portion 34 which is attached to at least onesidewall structure 36 forming part of the packing structure 10. Thesidewall structure 36 forms at least a portion of an enclosure 35 which,when viewed from the direction in which the article 16 extends, isgenerally configured in the shape of the end portion 12a of the article.Such shapes may take the form of a polygon or of a an arcuate structuresuch as a circle or ellipse.

When the end portion 12a of the article 12 is a rectangularconfiguration, an upper sidewall 40 may be formed similar to a lowersidewall 38 but in a reverse orientation to the lower sidewall andintegral with the peripheral edge 34 at the other side of the flange 30from the lower sidewall. Also forming portions of the enclosure 35 is aforward sidewall 44 along and integral with the forward side of theperipheral edge 34 of the flange 30 and a rear sidewall 46 positioned onthe other side of the flange from the forward sidewall. The enclosure 35formed by the sidewalls extends about the end portion 12a of the article12 to hold the article in a suspended relationship relative to thecontainer 12 16.

The forward and rearward sidewalls 44, 46 are configured differentlyfrom the lower and upper sidewalls 36 38, 40. As is described below, thedifference in configuration is important in the dissipation of theshocks applied to the package. Also the packaging structure conforms tothe shape of the end portion 12a of the article 12 to reduce the size ofthe packaging structure. However, components and features which areshared by the sidewalls 38, 40, 44, 46 have been designated withidentical references reference numerals.

Referring also to FIG. 2, the sidewall structures 38-46 have an innerwall 48 with a distal end portion 50 which is integral with theperipheral edge portion 34 of the flange 30. The inner wall 48 extendsinward inwardly from the flange 30 and about the end portion 12a of thearticle 12. The sidewall structures 38-46, have outer walls 54 which arespaced from the inner walls 48 to form a hollow cushion spacing 55. Aproximal end 56 of the outer wall 54 is joined to a proximal end 58 ofthe inner wall 48 by a transverse bridge section 60. Referring back toFIG. 1, a distal end portion 61 of the outer wall 54 supportinglycontacts the top wall 22, bottom wall 24 and front and back sidewalls26, 28 of the container 12. As best shown in FIG. 3, preferably thedistal end portion 61 is vertically aligned with the flange 30. Theinner wall 48 and outer wall 54 are formed with a slight draft as thewalls extend inward, so that a number of packaging structures 10 may benestingly stacked during storage.

To allow shocks to be dissipated through the structure 10, the structureis formed of a flexible, resilient, preferably polymeric material. Theshocks are primarily dissipated by the flexibility and resiliency of thebridge section 60 which forms a biasing and dampening arrangement 62 tomaintain the cushion separation of the outer wall 54 from the inner wall48 during shock loading. Should shock loading of the article 12 cause aforce to be applied by the article on the inner wall 48 therebydeforming the inner wall and moving the inner wall toward the outer wall54, the flexing and resiliency of the bridge section 60 causes thebridge section to apply an opposing biasing force on the inner wall todissipate the shock loading force.

In addition, after flexing, the resiliency of the material causes theinner wall 48 and outer wall 54 to return or recover to their originalshape and position. An advantage of this flexibility and resiliency isthat the present packaging structure 10 may absorb repeated shockimpacts without deteriorating. Preferably the bridge section 60 isformed with an arcuate, generally semicircular cross sectionalcross-sectional configuration so that the flexing of the bridge isspread over the length of the bridge. The bridge section 60 may also beformed with planar portions.

Any of a number of polymeric materials can be utilized to form theunitary packing structure 10. Generally such materials will becharacterized by the physical properties of durability, elasticity, or“memory”, high and low stability, and thermoformability. Particularlyuseful for forming the unitary packing structure 10 is high densitypolyethylene (HDPE), although other polymeric materials may be equallysuitable, depending upon the application. High density polyethylenegenerally has a stiffness of about 150,000 PSI. This provides sufficientflexibility for the purposes of the present invention and sufficientresiliency so that the packaging structure 10 returns or recovers to itsoriginal loaded or less stress state following absorption of a shock. Ifdesired, the HDPE used in making the packaging structure 10 may berecycled, post-consumer material.

It will be noted that the end portion 12a of the shock sensitive article12 is in a relatively tight fit against the inner walls 48 of the lowersidewall 38, upper sidewall 40, forward sidewall 44 and rearwardsidewall 46. Indeed, for better shock protection, it is preferred thatthe inner walls 48 be adapted and integral with the peripheral edgeportion 34 of the flange 30 to pressingly engage and hold the article 12when the article is positioned within the sidewalls.

It will also be noted that with the lower sidewall 38, upper sidewall40, forward sidewall 44 and rearward sidewall 46 forming the enclosure35 which surrounds the end portion 12a, shocks which are applied to thearticle 12 in a direction generally parallel to the flange 30, such asby dropping the container 16, will be primarily absorbed and dissipatedby the flexure and resiliency of the bridge section 60 and inner andouter walls 48, 54 of one or more of the sidewalls.

Referring to FIG. 2, the lateral edge 64 of the inner wall 48, lateraledge 66 of the bridge section 60 and lateral edge 68 of the outer wall54 are integral with and connected to end faces 70.

Referring back to FIG. 2, it has also been found that the greater thelongitudinal length of a wall such as the outer wall 54 or inner wall48, the greater the flexibility and less resiliency of a portion of thewall the farther that portion is away from the lateral edges 64, 68 ofthe wall. For example, the midpoint of the inner wall 48 or outer wall54 between the lateral edges 66, 68 typically is the most flexible andhas the least resiliency. In certain instances the portion may have toomuch flexibility to absorb shocks. Thus, in the preferred embodiment,intermediate resilient strength corners 80 are formed in the lowersidewall and upper sidewall 40 by forming a notch 82 in a middle portion84 of the sidewalls. The strength corners 80 are defined by theconnection between intermediate faces 86, which are integrally connectedto and extend between the inner wall 48, outer wall 54 and bridgesection 60, and the bridge section 60 of the notch 82.

The packaging structure 10 is preferable preferably thermoformed from asheet of polymeric material which is transformed into the packingstructure. The sheet would generally be from 10 to about 90 gauge (MILS)in thickness. In addition to thermoforming, it is contemplating that thepackaging structure 10 may also be produced by injection molding.Regardless of the method of manufacturing, the particular thickness ofthe polymeric material making up the sidewalls 38, 40, 44, and 46 is afunction of the specific properties of the polymeric material itself andthe weight and shape of the shock sensitive article.

As is well known, in the typical thermoforming process the thickness ofthe various components of the article is dependent on the initialthickness of the sheet of polymeric material and also the surface areaof the component which is formed from that sheet. For example, in thepackaging structure 10, the farther inward a sidewall, such as the uppersidewall 40, extends from the flange 30 the more surface area of thesidewall. The more surface area, the thinner the sidewall becomes. Asthe walls become thinner, the flexibility increases and the resiliencytends to decrease. Therefore, in the preferred embodiment, the lowersidewall 38, upper sidewall 40, forward sidewall 44 and rearwardsidewall 46 are uniquely configured to vary the thickness of thematerial along the length of the sidewall thereby enhancing the shockabsorbing characteristics of the packaging structure 10. For example, asnoted above, a middle portion 84 of the upper and lower sidewalls 38, 40tends to have greater flexibility and less resiliency than end portions88 of those sidewalls. By forming the notch 82, the middle portion 84extends inward from the flange 30 for less distance than the endportions 88. Thus, the inner wall 48 and outer wall 54 of the middleportion 84 is typically thicker than the inner wall 48 and outer wall 54of the outer portions 88 which decreases the elasticity and increasesthe resiliency and shock absorbing characteristics of the middle portion84.

When packaging a shock sensitive article 12 having a plank likerectangular configuration, the forward sidewall 44 and rear sidewall 46have a much shorter longitudinal length than the upper sidewall 40 andlower sidewall 36 38. The short longitudinal length places the two endfaces in close proximity to each other potentially causing the innerwall 48 to be too rigid thereby lessening the shock absorbingcharacteristics of those sidewalls. To increase the flexibility of theinner wall 48, a middle portion 94 of the forward and rear sidewalls 44,46 is extended inward a greater distance than the outer portions 96 andforms a middle shoulder 98. The increase in height of the middle portion94 decreases the wall thickness of the middle portion thereby decreasingthe resiliency and increasing the flexibility of the inner wall 48,outer wall 54 and bridge section 60 to enhance the shock absorbingcharacteristics.

The sides of the shoulder 98 are formed by intermediate faces 100 whichare integrally connected to and extend between the inner wall 48, outerwall 54 and bridge section 60. Corners 101 are formed at the connectionof the faces 100 and bridge section 60 of the sidewalls 44, 46. Thecorners 101 strengthens the forward and rear sidewalls 44, 46.

Referring to FIG. 2, the packaging structure 10 can be formed so thatthe lower sidewall 36 38, upper sidewall 40, forward sidewall 44 andrearward sidewall 46 may independently absorb shocks applied to theshock sensitive article 12 by being separated from each other by lands102. The intersection of the lands 102 and end faces 70 also formresilient strength corners 103 to resiliently maintain the separation ofthe inner wall 48 from the outer wall 54 during shock loading of thearticle.

The lands may be aligned with the flange 30 preferably by beingco-planar with the flange. It is also contemplated that the sidewalls,for example the lower sidewall 36 38, may be composed of one or moresegments of sidewalls, separated by lands 102.

Referring to FIGS. 2 and 3, the packaging structure 10 is also formedwith at least one crush depression or crush button 110 for absorbingshocks which are applied to the article 12 in a direction generallynormal to the plane of the flange 30 or along the longitudinal length ofthe article 12. The crush button 110 is formed with lower end face 112which is configured to contactingly engage the left lateral sidewall 18(FIG. 1) and right lateral sidewall 20. The distance between the flange30 and the sidewall 18 established by the button 110 defines a cushiondistance “d”.

The end face 112 is integrally connected to the flange 30 by a sidewall114. For stability, the crush button 110 is located within the sidewalls36 38, 40, 44, 46. The crush button 110 primarily dissipates shocksapplied to the shock absorbing article 12 by flexing and deformation ofthe sidewall 114. The elasticity of the material forming the sidewall114 allows the packaging structure 10 to accommodate repeated shocks.

The packaging structure 10 is preferably formed with three crush buttonbuttons 110, each having a generally rectangular cross sectionalconfiguration such that four rounded corners 120 extend from the flange30 to the end face 112 for each button. The corners 120 form strengthpillars 121 for increases strength. In addition, channels 122 may extendbetween adjacent buttons 110. At the juncture 124 of the channels 122and crush buttons, additional strength corners 126 are formed toincrease the strength of the buttons 110.

Referring now to FIG. 1, if an end portion 12a of an article ispositioned within a unitary packing structure 10, and the opposing endportion 12b is placed within another such structure 14, and thecombination of the packaging structure and shock sensitive article isplaced in the container 14 16, a typical shipping arrangement willresult. To facilitate the insertion of the packaging structure into thecontainer 14 16, corner notches or radii 128 may be formed on all fourcorners.

If this arrangement is shocked, as by dropping it, there will be aresulting force downwardly upon the lower sidewall 36 38. In response tothe force, the inner wall 48 will be forcefully flexed and forced towardthe outer wall 54, which contacts one of the longitudinal walls 22-28,causing a flexing of the bridge portion 60. The force applied to thesidewall 36 38is then dampened and dissipated through the flexure andresiliency or the inner wall 48 and the exertion of the opposing forceapplied by the bridge section 60. After the force has been dissipated,the elasticity of the sidewall 36 38and resiliency of the bridge section60 causes the sidewall to return to its original configuration.

Should the shock loading force by applied generally toward a lateralsidewall 18, 20, for example by dropping the container on an end, thesidewalls 114 of the crush buttons 110 may bow to absorb and dissipatethe shock. After the shock has been dissipated the sidewalls 114 recoverdue to the resiliency.

Referring to FIG. 4, an alternate embodiment of the unitary packingstructure is generally indicated at 200. The packing structure 200 issimilar to the packing structure 10 (FIG. 1), but also includes at leastone and preferably a plurality of foldable, shock absorbing flaps 202.The flap includes a planar leaf 204 integrally attached to at least oneshock absorbing protrusion 205 such as crush button 206.

The flap 202 is preferably integrally and hingably attached to thedistal end portion 61 so that it may fold from a first or straightenedposition, wherein the leaf 204 is generally co-planar with the flange30, to a second or folded position 202a. In the folded position 202a,the leaf extends below the flange 30and the crush buttons 206 arepositioned below one of the sidewall structures 36. Also, in the foldedposition 202a, crush buttons 206 and the crush buttons 110 contactinglyengage the lateral sidewall 20 of the container 16 to establish thecushion distance d between the flange 30 and sidewall 20.

The crush buttons 206 may be similarly configured to the crush buttons110 and include an end face 208 and sidewalls 210. For stability, theflap 202 is preferably formed with a plurality of crush buttons 206which are eveningly distributed along the surface of the leaf 204. Inaddition, the leaf 204 is dimensioned and the crush buttons 206 arepositioned so that when the flap 202 is folded, the crush buttons 206are disposed between the crush buttons 110 and distal end 61.

Referring also to FIG. 2, the flap 202 may be attached to the distal endportion 61 adjacent any of the sidewalls 36, 40, 44, 46. Also, thepacking structure 200 may be formed with one flap 202 or a plurality offlaps depending on desired shock absorbing characteristics. For example,the packaging structure 200 may include two flaps attached to distalportion 61 of opposite sidewalls 36. The flaps 202 provide additionalcushioning against shock loading forces which are applied to container16 at a location in close proximity to an edge 214 between two sidewallssuch as sidewall 20 and longitudinal sidewall 28. The shock absorbingprotrusion 205 may also be formed in other configurations such as ashape which mimics the configuration of the sidewall structures 36.

A specific embodiment of the novel packaging for fragile articles withina container according to the present invention has been described forthe purposes of illustrating the manner in which the invention may bemade and used. It should be understood that implementation of othervariations, and modifications of the invention in its various aspectswill be apparent to those skilled the art, and that the invention is notlimited by the specific embodiment described. It is thereforecontemplated to cover by the present invention any and allmodifications, variations, or equivalents that fall within the truespirit and scope of the basic underlying principles disclosed andclaimed herein.

What is claimed is:
 1. A unitary structure for packaging a shocksensitive article within a container comprising: a side flange having aperipheral portion; a first peripheral sidewall structure of flexiblematerial, said sidewall structure including an inboard wall integralwith said peripheral portion and extending over an end a portion of thearticle, an outboard wall having a distal end and a proximate end, and abridge section integral with said inboard wall and said proximate end ofsaid outboard wall and spacing said outboard wall from said inboard wallto form a cushion space, said bridge section forming biasing means toresiliently restrict the movement of said inboard wall toward saidoutboard wall upon the shock loading of said article; and means forabsorbing shock loading of the article generally in a first directionaway from the article, said shock absorbing means including a at leastone crush depression integral with said flange, and generally extendingfrom said flange in the first direction to supportingly contact a sidewall of the container and form a cushion distance.
 2. The structure ofclaim 1 wherein said depression extends in the first direction relativeto said flange for a greater distance than said distal end of saidoutward wall.
 3. The structure of claim 1 further including a secondperipheral sidewall structure extending over the end portion of thearticle, integral with said peripheral portion and separated from saidfirst wall structure along said peripheral edge portion of said flange.4. The structure of claim 3 wherein said structure includes landsintegral with said peripheral portion, said lands generally aligned withand extending outward from said flange to separate said first peripheralwall from said second peripheral wall.
 5. The structure of claim 3wherein said second sidewall structure is integral with said edgeportion on an opposite side of said flange from said first sidewallstructure.
 6. The structure of claim 5 wherein said at least onedepression is formed between said first sidewall and said secondsidewall.
 7. The structure of claim 1 wherein said first peripheral wallincludes lateral end faces integral with said inboard wall, saidoutboard wall and said bridge section.
 8. The structure of claim 1wherein the cushion space is hollow.
 9. The structure of claim 1 whereinsaid first sidewall forms a notch along the length of said sidewall. 10.The structure of claim 9 wherein said notch is formed midway between endfaces of said sidewall.
 11. The structure of claim 1 wherein said firstsidewall forms an elevated shoulder along the length of said peripheralwall.
 12. The structure of claim 1 including at least one flap includinga second crush depression, said flap being integrally attached to adistal end portion of said sidewall structure.
 13. A unitary structurefor packaging a shock sensitive article within a container comprising: aside flange having a peripheral portion; a plurality of peripheralsidewall structure of flexible material, said sidewall structuresincluding an inboard wall integral with said peripheral portion withsaid sidewall structures arranged about the peripheral portion to forman enclosure about an end portion of the article, said sidewallstructures including an outboard wall having a distal end and aproximate end, and a bridge section integral with said inboard wall andsaid proximate end of said outboard wall and spacing said outboard wallfrom said inboard wall to form a hollow cushion space, said bridgesection forming biasing means to resiliently restrict the movement ofsaid inboard wall toward said outboard wall upon the shock loading ofsaid article; lands extending outward from said flange to separate saidsidewall structures form from each other; and a crush depressionintegral with said flange, inward of said first wall and generallyextending in a first direction from said flange away from the article tosupportingly contact a sidewall of the container and form a cushiondistance, said button crush depression including means for absorbingshock loading of the article generally in the first direction.
 14. Apackaging structure for packaging an article within a containercomprising: a flange for receiving a portion of the article, said flangedefining a flange plane extending along the length thereof; an outerflange for positioning said packaging structure within the container,wherein said outer flange is substantially coplanar with said flangeplane and extends along an outer periphery of said packaging structure;at least one sidewall portion attached to said flange and positionedbetween said flange and said outer flange, said at least one sidewallportion being configured and arranged to provide shock protection to atleast a portion of the article when the article is positioned on a firstside of said flange plane; and at least one hollow crush button forproviding shock protection to at least a portion of the article, said atleast one crush button extending at least partially from a second sideof said flange plane, wherein said second side is opposite to said firstside; said at least one sidewall portion forming an enclosure, with saidflange and said crush button being positioned within said enclosure andsaid outer flange being positioned outside of said enclosure.
 15. Thepackaging structure of claim 14 wherein said at least one crush buttonincludes an end face, wherein when said packaging structure is securedby lateral sidewalls of the container, said end face is positionedcloser to an endwall of the container than other portions of saidpackaging structure.
 16. The packaging structure of claim 14 furtherincluding a plurality of crush buttons, with at least one channelextending between two of said crush buttons.
 17. The packaging structureof claim 14 wherein said at least one crush button is of a generallypolygonal shaped cross-section, and includes strength pillars formed ateach corner thereof.
 18. The packaging structure of claim 14 whereinsaid flange, said at least one sidewall portion and said at least onecrush button are integrally formed from a single layer of material. 19.The packaging structure of claim 14 wherein said at least one sidewallportion has a particular resiliency, and said at least one sidewallportion also includes a notch formed therein for adjusting saidparticular resiliency of said at least one sidewall portion.
 20. Apackaging structure for packaging an article within a containercomprising: a flange for receiving a portion of the article, said flangedefining a flange plane extending along the length thereof; at least onesidewall portion attached to said flange, said at least one sidewallportion being configured and arranged to extend in a first directionalong a side of the article and to provide shock protection to at leasta portion of the article when the article is positioned on a first sideof said flange plane; and wherein said at least one sidewall portionincludes a middle portion extending in said first direction between twoshoulder portions, said middle portion being bounded in said firstdirection by two faces extending generally transverse to said firstdirection such that said middle portion has a height with respect tosaid flange plane that is greater than said two shoulder portions andsaid middle portion has a different resiliency than said two shoulderportions, wherein said different resiliency of said middle portion iscreated because said middle portion has a wall thickness that isdifferent from a wall thickness of said shoulder portions.